Selecting the Right Boiler Type for

the Application

Presented by Steve Connor

May 29, 2013
 Steam Boilers for the Process Industry

Firetube Watertube

Packaged Industrial

Single pass Membrane Wall

horizontal

Flexible
Vertical
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 Motive Force

3
 Motive Force

4
 Motive Force

Photo credited to www.geothermal.marin.org/geopresentation/images/img038.jpg

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 Heat Absorbers

Shell & Tube Plate & Frame

Copyright Southern Heat Exchanger Corporation

Photo credit: www.allnesales.com

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 Heat Absorbers

Absorption Chiller Corrugating Machine

Photo credit: www.thermotechgp.com Photo credit: www.weiku.com

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 Heat Absorbers

Autoclave

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 Heat Absorbers

Jacketed Kettle

Photo credit: www.marketforge.sterilizers.com

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 Heat Application

Petrochemical
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 Heat Application

Paper Wood laminate Corrugated boxes

Pulp & Paper

Photo by Kristopher Hite 11
 Heat Application

Microelectronics
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 Heat Application

Food & Beverage

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 Heat & Pressure

Pharmaceuticals
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15
Most Common Need Issues

Varying plant load Retrofit within existing

Seasonal fluctuations building

Large capacity Limited budget

Very high steam Control Fuel cost

pressure requirement Emissions

High quality steam Advanced controls

(minimal moisture)

Limited space and

headroom
 Varying plant load (Rapid
swings)
Large capacity (300,000
#/HR)
Very high steam pressure
(500#)
High quality steam (<1/2%)
Limited budget

Scenario One
 Scenario 1
Large Capacity: Single Unit or Multiples

Characteristics
Varying plant load
Rapid swings

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 Scenario 1
Making the choice between Firetube and Watertube

Characteristics
Large capacity: 300,000 lb/hr
High operating pressure: 500 lb
Budget

A D O

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 Scenario 1
Drum Internals for Steam Quality

Characteristics
High quality steam:
< % moisture

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 Scenario 1
Convection Superheater D Style

Saturated Steam
600 Psig, 4850 F.
Add 3000 F of SH

Superheated Steam
7850 F. for process

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 Varying plant load
(modulation)
Limited budget
Control fuel cost

Scenario Two
 Scenario 2
Firetube with Integral and Packaged Burner

Characteristics
Limited budget
Control fuel cost

Packaged (gun burner) Unit Integral Package

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 Scenario 2
Turndown and Lead Lag Control

Characteristics
Varying plant load

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 Seasonal fluctuations
Limited space and headroom
Limited budget
Control fuel cost (key issue)

Scenario Three
 Scenario 3
Space Reduction, Reduce Fuel Cost, Limited Budget

ules Of Thumb Philosophy

Five Square Foot Rule Of Heating Surface

Number of passes, Four vs Three vs Two

available Sophisticated Modeling

Sophisticated modeling did not exist or was not
nancially feasible
Relied on trial and error from the field or R&D lab

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 Scenario 3
Key Elements of Advancement to Create the Solution

Combustion Furnace Heat Transfer

Performance Geometry Of The Tubes

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 Scenario 3
Space Reduction, Reduce Fuel Cost, Limited Budget

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 Scenario 3
Space Reduction, Reduce Fuel Cost, Limited Budget

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 Scenario 3
Space Reduction, Reduce Fuel Cost, Limited Budget

High turndown
Typical Boiler
while
Firing Range
maintaining 3%
O2 across the
firing range*

* CBEX Elite Boilers 100-800 HP

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 Scenario 3
Space Reduction, Reduce Fuel Cost, Limited Budget

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 Scenario 3
Linkage Limitations

Single Point Positioning

Single air curve

Slip and stretch
Wear
Non-repeatable

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 Scenario 3
Space Reduction, Reduce Fuel Cost, Limited Budget

Parallel Positioning

Separate fuel settings

Precise control
Eliminates slip and stretch
Repeatable

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 Scenario 3
Space Reduction, Reduce Fuel Cost, Limited Budget

Time
Temperature
Turbulence

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 Scenario 3
Space Reduction, Reduce Fuel Cost, Limited Budget

Radiation
Conduction
Convection

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 Scenario 3
Space Reduction, Reduce Fuel Cost, Limited Budget

Convection
Heat transfer
Inertial forces
Non-viscous

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 Scenario 3
Space Reduction, Reduce Fuel Cost, Limited Budget

Typical Boiler Tube

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 Scenario 3
Space Reduction, Reduce Fuel Cost, Limited Budget

Cleaver-Brooks Advanced
Heat Transfer Tube

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 Scenario 3
Seasonal Fluctuations and Limited Budget

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 Scenario 3
Seasonal Fluctuations and Limited Budget

Most Cost Effective

Integral Burner

Gun Burner
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 Scenario 3
Seasonal Fluctuations and Limited Budget

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 Scenario 3
Seasonal Fluctuations in Load

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 Scenario 3
Seasonal Fluctuations in Load

Summer Boilers
Avoid cycling of large
boilers
Recognize dramatic fuel
savings

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 Retrofit within existing
building
Limited budget

Scenario Four
 Scenario 4
Retrofit Options

Advantages
Small boiler profile and
footprint
Can be field-erected

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 Emissions reduction
Advanced controls

Scenario Five
 Scenario 5
Emission Control

Low-NOx Burner

SCR

FGR

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 Scenario 5
Advanced Controls

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 Final Summary

Process boilers are found in countless applications

spanning countless industries
Fuel is a major cost within the total operating budget
FT & IWT boilers have distinct advantages/disadvantages
FT boilers are evolving; more efficient, smaller, lighter
Holding 3% O2 across the firing range is now possible
When budgets are tight the alternative is the gun burner
package.
Understand the load conditions and consider a smaller
boiler for the summer load.
NOx reduction has arrived with FGR and SCR packages
Advanced controls for new or retrofit provide energy
savings, improved reliability and safety.

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Contacts for additional Information:

Florian Wisinski
Product Manager Firetube Boilers
fwisinski@cleaverbrooks.com
(414) 577-2982j

cleaverbrooks.com

Jason Jacobi
Product Manager Watertube Boilers
jjacobi@cleaverbrooks.com
(402) 434-2032

cleaverbrooks.com

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